Water softener



May 10 1927 o. w. JOHNSON WATER S OFTENER Filed 001'.. l, 19,26.`

i ciable hardness.

Patented vMay-10, 1927..

OSCAR W. JOHNSON, BOCKFORD, ILLINOIS, ASSIGNB T wann-Lovin rum oon-POBA'IION, 0F ROOKFOBAD, ILLINOIS, CORPORATION 0F ILLINOIS.

WATER sor'rnnnn.

Application ma october 1, 1926. serial m.` issso. c

This invention `relates to water 'softeners operating on the'base-exchange principle.

. It is the main object of the present invention to provide a novelmethod of operating a Water softener as well as a new construction of awater softener designed for lsuch operation,.whereby to enable 'securingwater of zerol hardness immediately after, regeneration. In l the. past,this was not obtainable because of the lime-laden condition of a partofthe mineral at the end of the bed of zeolite caused by the passing ofhard water with the brine through the bed during regeneration. lhe layerof exhausted mineral, being disposed at the outlet end of the bed asrespects the normal direction of flow for softening, transferredits-hardness to the 'water after its passage through the bed forsoftening. Thus the .20 Water which would otherwise be'- supplied tothesystem as thoroughly softened water were it not for its contact with thelime of the exhausted mineral just upon leaving the softener, was foundby test to show appre- I'n fact, water of zero hardness could not beobtained until practically all of the lime in the layer of er.` haustedsoftened water in coursing through it on 30,' leaving the softener.

Accordingto the present invention, which contem lates a softeneroperating with upward ow, I 'provide a water softener of suchconstruction that, at the endl of the regenerating operationf whenthegbrine is drained from the softener tank, a certainamount of brinewillA be left in the bottom ofthe tank to 'be carried n wardl'y throughthe bedtof zeolite'with the water in the 4o yflushing, operation, thisbrine being of a' suicient quantity to regenerate whatever amountofmineral in the bed was exhausted wholly or partially by the@ passageof the hard water with lthe brine therethrough Y gduring regeneration.Consequently, there is "no lime left in the upper portion of the bed aswas otherwise the case andthe water, after passing through the bed forsoftening, not be turned hard but will issue as so water of zerohardness. The softener, i111-,

mediatel after regeneration, will, therefore, Vsupply e desired softwater and there willY Y.not be a period where traces of hardness areevident. As will presently appear, the

desired operation'just described 1s vsecured mineral had beenassimilated by the vwithin a short distance of the to simply' by.`locating the lower ypipe connection on the softener tank at a levelsuliciently above the bottom of the tank so as to leave a predeterminedamount of brine therein at the close of the regenerating oper-.

ation. I also prefer to provide, along vwith i this pipe connection,meansfor directing the incoming iu'shing water downwardly to- Ward thebottom of the tank/to insure picking u the brine for passage upwardlythrong the mineral bed.

rlhe invention is' illustrated .in the accompanying drawing, wherein-eFigure 1 is a side view of a water softener installation showing'thelower part of the 70 softener tank in central vertical section toillustrate the novel features incorporated in accordance with myinvention. An interme'- diate portion. of the tank and pipeconnectionsisbroken away to enable showing the parts on a larger scale;

Fig. 2 is .a 'View corresponding to the Ilower part of Fig. 1'illustrating a modified or alternative constructionin the meansemployed for 4directing the incoming water 80 downwardly toward thebottom of the tank; anc l f l Fig. 3 is a horizontal section ona'con'siderablyreduced scale of the bottom portion of'the tankillustrating a still further modi- 35 fied or alternative form of meansfor the purpose last referred to, this particular construction beingespecially designed for use. on larger units. l

Alimilarreference numerals are applied to' 'go corresponding parts inthe three views. l

Referring for the present morev particul larly to Fig. 1, the softenerillustrated is, for the most part,- similar in construction to thatdisclosed in my copen'ding application, 95

Serial No. 46,198, filed July 27, `1925, and comprises a base 3 havingsupportinglegs 4c and a boltingilange 5 to which `tlxe'iiaiige t "6 ofthe tank 7 is secured by bolts 8. Thev ltank contains the bed of zeoliteor base-ex- '100 p change water softening material. IThe maj, terial inthe present case extends. up to of the tank, as 'indicated by the dotted'lme'at 9, Y

and provision is 'made at the bottom for .10.51.,

filtering and evenly distributing the 'waterafter .entering the tank forpassage up wardly through the material. A filter cloth 10 of. very linemesh is provided between reinforcing grids 11 to serve the purposes 11omentioned. The headl space in the tank above the material allowsthematerial to settle so as not to be carried off through the outlet andalso furnishes aV space for the reception of the regenerating orreconditioning material, such as common salt or salt brine, which may bepoured or injected into the tank when the softener is to be regenerated.The neck portion 12 of the tank is fitted with a salt cap 13 which isapplied and removed from the tank by ethe handles 14. Hard water isreceived through un inlet pipe 15 leading in from the city7- mains atthe users disposal. The pipe l5 is connected with a system of pipefittings lo extending vertically alongside the tank and is arranged tocommunicate therethrough with the base 3 of the tank, as by means of alower pipe connection 17. lThe latteris threadedly received in anopening 18 in the base 3 of the tank. The pipe 15 also coinmunicatesthrough the pipe fittings 16 with the top of the tank through an upperpipe connection 19 threading into the neck12, as shown. The softenedwater leaves the tank through an outlet pipe 2O tapped into the pipefittings 16 above the inlet pipe 15. A

valve 21 is interposed in the outlet pipe and another walve 22 isinterposed in the pipe fittings 1G between the inlet and outlet pipes 15and 2() respectively. From the description thus rfar advanced, it willappear that water entering the inlet )ipe 15 and flowing down throughthe pipe ttings 16, the valve 21 being assumed open, flows upwardlythrough the tank and is discharged through the outlet pipe 2,0. Thiscorresponds to the normal flow through the softener' in softening. Thepipe 2O is, of course, assumed to be in communication with the usualservice system to be supplied with soft water.

A Valve 23 is IOvded below the inlet pipe 15 to shut o the normal flowthrough the softener and to enable reversing' the direction of flow byVopening the valve 22 during regeneration. .Below the valve 23 a faucetor bib 24 is tapped into the pipe fittings 16 and discharges into anatmospheric timing funnel 25. The latter is carried by a standpipe 26tapped into a waste pipe 27 on the discharge side of a valve 28 whichcontrols the discharge of water from the tank through the waste pipewhen draining the tank. It will now appear that the regeneratingoperation ma e carried out as follows z-all of thel va ves, namely 21,22, 23, 24, and 28 will be closed. The

bib 24 will then be o ened which start-s a flow of Water into the e1 A25which stops as soon as the pressure of the'line com-` municating withthe inlet pipel 15 is released from the tank. The salt cap' f1?) is thenremoved and the proper amount of salt or bring is introduced into thetank. Upon the removal of the salt cap; there is ob-v "'material.

viously La flow from the bib 24 and suffe. cient water is drained fromthe tank to permit the introduction of salt or brine, as the case maybe. The salt cap, after the introduction of the salt or brine, isreplaced and the hib 24 is closed to prevent further drainage. Thereuponan air valve 29, communicating with the system of pipe fittings 16,adjacent the upper ipe connection 19, is opened and the same 1s true ofthe valve 75 This allows the tankto refillso that there is Water presentsufficient to assimilate the salt. As soon as water flows from anoverflow pipe 30, which communicates with the air valve 29, anddischarges into the funnel 25, the air valve is closed and thereuponthevalve 23 is closed. This is to avoid the wasting of any brine. The valve22 is then opened so as to allow hard water to enter the top of thesoftener tank to wash the salt down through the mineral bed. The bib 24is opened and adjusted to maintain a certain predetermined level in thefunnel 25 thereby avoiding the likelihood of the brine being passedthrough the mineral bed at anything beyond 'a certain rate. It isunderstood that a certain time element is involved and it is wasteful,therefore, to pass regenerating fluid through the mineral any fasterthan an exchanne can properly occur between it and the so eniner Afterthe salt has been washed v down through the mineral bed for a' certainspecified length of time, usually about thirty minutes in the case ofthe average sized household unit, the valve`22 is closed as it isassumed that sufficient brine has then been passed through the mineralbed to completelyT restore it to its full softening capacity. t is,however, important to note at this oint that, as a result of the passingof the iard water down through the mineral bed in order to carry thesalt or brine downwardly therethrough, the head space in the tank at theclose of the regenerating operation and prior to the flushing operation,to be next referred to, is filled with hard `water. The mineral bed has,as a result of the pas-V sage of the hard water, suffered a certainamount of exhaustion at the top thereof and the mineral at this point isconsaplently lime-laden. In accordance with the usual practice, the hardwater in the head space above the mineral was flushed out after theregenerating operation in what was termed the backwash, flushing orwashing operation. That is, hard water was caused to flow upwardlythrough the mineral so as to be softened and then displace the hardwater from the head space out through a waste outlet. In other words,the object was to eliminate any Lard water fromthe softener so that whenthe softener was again connected with the service system there would beno hard water injected into the system.

,secure water of zero It was `found, however, that the lime-laden.condition of the mineral at the top of the i A bed turnedthe softenedwater into hard water and it was im ossible, therefore, to ardnessimmediately after regeneration. The water on actual test afterregeneration would show appreciable hardness.- In fact, it would takesome .timebefore water of zero hardness could be l0 robtained asractically all of the lime in the 33 nection 17 .i

.layer of e austed mineral had to be assimilated by the softened' waterbefore truly soft water could be secured, This is readily understoodwhenit is considered that the hard water, in passing through the mineralfrom the bottom upwardly, is converted into l water of zero hardness andas'a result will vthen have .considerably -anity for lime. In fact," itmay be stated that-#such water is in 'a nascent condition and "willgeadily assimilate the lime upon coming in contact with it at the outletend of the bed .Ac-

cording to the present invention, as will now be described, I make a'provision whereby a certain amount of brine is reserved at the end ofthe regenerating operation for passage back through the mineral bed withthe flushingl water, the brine being in a sufficient quantity toregenerate whatever 0V amount of mineral in the bed was exhausted whollyor partially by the passage of the hard water with the brine through thesame in the regenerating operation.`

According to my invention, the pipe oo ndisposed an appreciable distanceabove the actual bottom ofthe tank so as t'oleave a predetermined amountof brine therein when the tank is-drained at 'the close 'of theregenerating operation and noted thatthebase 3 is dished or basinshapedto provide a rounded basin bottom or hollow 31. The opening 18 for thepipe connection 17 is at an appreciable elevathe rim portion thereof, asshown. At the close of the regeneratino' operation, the

' valve 28 is opened to esta lish communication between thebottom of thetank and the lwaste pipe 27.A The air valve 29 isthen opened whereuponthe tank will-drain in an `obvious manner. The hard water 1n y I theheadspace-,"or the most part, is softened being loweredinto the mineral bedas,

level )is permitted to drop usually to v mayf be made to insure thelowering of the level in the tank to this point as the valve 28 maybeclosed and the bib 24 opened. Thenif there is still a flow from the ybib24,

-itf is 'evident that ,the level has not been dropped suiciently. Whenthe draining .is completed, the lvalve 28, aswell asthe bib 24, isclosed.' It is obvious' that the locaprior'to the flushing operation.-`It will betion with respect to the'basin 31 and near,

about the level of the bib 24'. .Actual testsV tion of the lowerV pipeconnection 17at such an elevation above the bottom of the tank insuresthe presence of a certain amount of brine in the bottom of the tank inthe basin 31 as there is no way for this brine to be ,drained outthrough the .waste pipe' 27 Thisl is picked up b the flushing water inthe backvfas'h or ilusliing operation and carried upwardly through themineral bed and serves to regenerate the layer or strata of exhaustedmineral at the top of the bed. In the iiushing operation, the air valve29 is left open and the valve 23 is then opened so that the brine in thebottom of the tank 'will be picked up b the flushing water and carriedupwardly t rouvh the mineral bed. The brine thus .encouiiters theexhausted mineral at the to of the bed and revives the same. The ushingwater with the brine then esca es through the upper pipe connection 19trough valve 29 `and overflow pipe 30 into the funnel 25 and thence tothe waste pipe 27. The flow is continued until the water tests softwhereupon theair valve 29 is closed and the valve 21 opened to restoreconnection with the service system.

I prefer to provide means alongwith the' lower pipe, connection 17 todirect the'incoming water downwardly so as to make- .certain that thebrine in the/bottom of the tank will be picked up. Obviously, a

variety of means may be employed for-this purpose. In Fi ..1 a lead-inpipe 32 is illustrated thre'a ing in'the opening 18 and having' an elbow33 'at the inner end thereof directed downwardly toward'the center ofthe,` basin bottom 31. This will insure the picking up of the brine sothat it will be entrained with the flushing water as it passes upwardlythrough the mineral bed. I prefer, however, toprovid'e a vbaiile plate34, as shown iuFig. 2, generally troughshaped and supported adjacent theopening 18 so as to direct the incoming water'.

approximately on a tangent along the side wall of the basin 31downwardly toward the center of the basin so as to pick up t e brine andcarry it alongv in the passagebf the water upwardly through the mineralbed. yThe baffle 34 is shown secured by screws '35 to the lower grid 11.In Fig. 3 a

pipe fitting 32 of cross form is shown com- As a result of thel absence.of any limei ladenmineral at theoutlet end of the bed,

f. o ud more saltI or brine than is otherwise usedand still theoperation of the softener is improved to a considerable extent, aspointed out above.

I claim:

l. The method yof operating a base-ex-Y change water softener whichconsists, first, in assing hard water through a zeolite ma terlal bedfor softening, second, passing brine orother reagent with hard waterthrough the bed of material in one direction for regenerating the same,and third, vpassing rhard water in the opposite direction through thebed to wash the same, the hard water being accompanied with a certainamount of brine or reagent suicient to re- Generate whatever amount ofmateriahin the bed was exhausted in whole or part by the passage of thehard water with the brine throufh the material during regeneration.

Q. 'lille method of operating a hase-exchange water softener whichconsists. first, in passing hard water in one direction through azeolite material bed for softening, second, passing brine or otherreagent with hard water in the opposite direction through the bed ofmaterial for regenerating the same, and third passing hard water throughthe bed in the reverse direction from the regeneration tiow, that is, inthe same direction as the softening flow, to wash the same, the hardwater being accompanied with a certain amount of brlne or reagentsufficient to regenerate whatever amount of material in the bed wasexhausted in whole or part due to the passage therethrough pf the hardwater with `the brine duringregeneration.

3. The iiiethod of operating a base-exchange water softener lwhichconsists, first. in passing hard water upwardly through a bed of zeolitematerial for softening, second. passing brine or other reagent with hardwater downwardly through the bed of material for regenerating the same,and

to wash'the same, the hard Water 5 el. In a water softener, a tank torsoftening material havingr pipe connections for the upper and lower endsthereof whereby to pass hard water upwardly through the material in thetank for softening, to pass brine downwardly through the material forvregenerating, and to pass hard water up through the material forflushing, the connection at the lower end of said tank beingsuiiiciently above the level of the bottom thereof to leave anVappreciable Avolume of brine in the bottom of said tank at the close ofthe regenerating operation and previous to the flushing operation, andmeans in conjunction with thc lower pipe connection for directing theincoming water downwardly before it passes u )wardly through the tankwhereby in i the up the brine'left in the bottom of the tank.

In a water softener as set forth in claim 4. wherein the bottom for saidtankis basinshaped and has the lower pipe connection near the rim ofsuch basin, the provision of the last mentioned means in conjunctionwith the lower pipe connection arranfred to direct the incoming waterdownwardly to `the bottom of said basin before it passes upwardlythrough the tank whereby in the flushing operation to pick up the brineleft in the bottom of thel tank in said basin.

6. In a water Softener as set forth in claim ,iwherein the bottom forsaid tank is basinshaped and has the lower pipe connection nearthe rimot such'basin, theprovision of the last, mentioned means adjacent saidpipe connect-.ion for deficcting the incoming water downwardly andinwardly toward the center ot the basin so as to pick up the brine leftin the bottom of the tank to be entrained with the water as it passes`upwardly through the material.

In witness of the foregoing I atiix my sig-- nature.

OSCAR W. JOHNSON.

ushing operation to pick'

